Chemically stable ceramic-metal composite membrane for hydrogen separation

ABSTRACT

A hydrogen permeation membrane is provided that can include a metal and a ceramic material mixed together. The metal can be Ni, Zr, Nb, Ta, Y, Pd, Fe, Cr, Co, V, or combinations thereof, and the ceramic material can have the formula: BaZr 1-x-y Y x T y O 3-δ  where 0≦x≦0.5, 0≦y≦0.5, (x+y)&gt;0; 0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Sn, or combinations thereof. A method of forming such a membrane is also provided. A method is also provided for extracting hydrogen from a feed stream.

PRIORITY INFORMATION

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 61/995,149 titled “A Novel Chemically StableCeramic-Metal Composite Membrane for Hydrogen Separation” of Chen, etal. filed on Apr. 3, 2014, the disclosure of which is incorporated byreference herein.

GOVERNMENT SUPPORT CLAUSE

This invention was made with government support under DE-SC0001061awarded by the US Department of Energy, 00102125 awarded by BattelleEnergy Alliance, LLC/US Department of Energy, and under B139006 awardedby the SC Universities Research & Education Foundation/SRNS/USDepartment of Energy. The government has certain rights in theinvention.

BACKGROUND

As an important raw material for the production of ammonia, methanol,and liquid hydrocarbons, hydrogen is mainly produced through catalyticsteam reforming of methane, which is strongly endothermic and requireshigh temperature (e.g., about 700° C. to about 900° C.) to achievemaximum conversion to H₂, CO, and CO₂ at high pressure (e.g., about 20bar to about 40 bar). High purity hydrogen can then be directly obtainedvia a separation step such as hydrogen permeation through aproton-conducting membrane under a pressure gradient at hightemperature. The application of membrane technology is expected toconsiderably reduce the capital and energy cost in hydrogen production.Composite membranes consisting of BaCeO₃-based proton conductor andelectronic conductor (e.g. nickel) have been developed for thisapplication. However, these membranes (e.g.Ni—BaZr_(0.8-x)Ce_(x)Y_(0.2)O_(3-δ) (Ni—BZCY), 0.4≦x≦0.8) sufferedserious performance loss in CO₂-containing environment at 900° C. due toreaction between BaCeO₃ and CO₂. U.S. Pat. No. 6,569,226 B1 issued toDoors et al. on May 27, 2004 discloses a hydrogen permeable compositemembrane based on hydrogen transporting metal and anon-proton-conducting ceramic, such as ZrO₂, Al₂O₃, BaTiO₃, and SrTiO₃.These ceramics only contribute to the mechanical strength of thecomposite membrane but not the hydrogen permeability. Among the protonconductors that are tolerant to CO₂, BaZr_(0.8)Y_(0.2)O_(3-δ)(BZY)-based materials possesses the highest bulk proton conductivity,and high mechanical strength.

SUMMARY

Objects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

A hydrogen permeation membrane is generally provided. In one embodiment,the hydrogen permeation membrane comprises: a metal and a ceramicmaterial mixed together. The metal can be Ni, Zr, Nb, Ta, Y, Pd, Fe, Cr,Co, V, or combinations thereof, and the ceramic material can have theformula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ)

where 0≦x≦0.5, 0≦y≦0.5, (x+y)>0; 0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo,Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Sn, or combinations thereof.

A method of forming a membrane is also generally provided. In oneembodiment, the method includes mixing a metal and a ceramic powder toform a metal-ceramic mixture; pressing the metal-ceramic mixture to forma composite membrane; and sintering the metal-ceramic mixture at atemperature of about 1100° C. to about 1700° C. The metal can be Ni, Zr,Nb, Ta, Y, Pd, Fe, Cr, Co, V, or a combination thereof, and the ceramicpowder can be a ceramic material having the formula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ)where 0≦x≦0.5, 0≦y≦0.5, (x+y)>0; 0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo,Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Sn, or combinations thereof.

A method is also generally provided for extracting hydrogen from a feedstream. In one embodiment, the method includes exposing the feed streamto a first side of a membrane at a temperature of about 600° C. to about1000° C., wherein the feed stream comprises hydrogen; and collectingpure hydrogen gas from a second side of the membrane opposite of thefirst side. The membrane comprises a metal and a ceramic material, withthe metal being Ni, Zr, Nb, Ta, Y, Pd, Fe, Cr, Co, V, or a combinationthereof. The ceramic material can have the formula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ), where 0≦x≦0.5, 0≦y≦0.5, (x+y)>0; 0≦δ≦0.5,and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Sn, orcombinations thereof.

Other features and aspects of the present invention are discussed ingreater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof to one skilled in the art, is set forth moreparticularly in the remainder of the specification, which includesreference to the accompanying figures.

FIG. 1 shows the cross-section SEM image of a sintered Ni—BZY membrane,according to the Examples. Ni particles (2˜10 μm) were embedded in thedense BZY ceramic matrix. The size of BZY grains is about 1 μm. Themembrane is very dense and free of pores.

FIG. 2 shows the time dependence of hydrogen flux of Ni—BZY membranesprepared by different methods measured in wet 20% H₂ at 900° C.according to the Examples. All membrane thickness is 0.40 mm. TheNi—BZY4 membrane shows very stable performance during the wholemeasurement process (about 160 h).

FIG. 3 shows time dependence of the hydrogen permeation flux of a0.40-mm-thick Ni—BZY4 membrane in wet 40% H₂ with 0, 30, 50% CO₂ at 900°C., according to the Examples. The membrane shows very stable and evenenhanced performance during the measurement in CO₂ (about 160 h).

FIG. 4 shows the XRD pattern of Ni—BZY4 membrane surface afterpermeation test in wet H₂ and CO₂ at 900° C., according to the Examples.The XRD patterns only shows XRD peaks corresponding to BZY or Ni phases,suggesting that Ni and BZY phases remained stable in wet 50% CO₂ at 900°C.

FIG. 5a shows a schematic for the synthesis and chemical stability testprocesses of BZYNiO2 and Ni—BZYNiO2 (denoted as Ni—BZY1 in Table 1).

FIG. 5b shows a schematic for the synthesis and chemical stability testprocesses of BaY₂NiO₅.

FIG. 6 shows XRD patterns obtained according to the Examples fromsurfaces of Ni—BZY1 after boiling for 20 h (a), Ni—BZY1 (b), Ni—BZY2(c), Ni—BZY3 (d), and Ni—BZY4 (e) membranes after annealing in wet 17%H₂ and 80% CO₂ at 900° C. for 50 h, where b: BZY (JCPDS 06-0399), n: Ni(JCPDS 04-0850), c: BaCO₃ (JCPDS 05-0378), and y: Y₂O₃ (JCPDS 41-1105).

FIG. 7 shows XRD patterns of fresh BaY₂NiO₅ powder (a), BaY₂NiO₅ powderafter annealing in CO₂ at 900° C. for 10 h (b), BaY₂NiO₅ powder afterannealing in dry H₂ at 900° C. for 20 h (c), BaY₂NiO₅ powder afterannealing in wet H₂ at 900° C. for 20 h (d), where b: BaY₂NiO₅ (JCPDS41-0463), c: BaCO₃, y: Y₂O₃, n: NiO (JCPDS 78-0643), B: BaY₂O₄ (JCPDS82-2319), N: Ni.

FIG. 8a shows Rietveld refinement for XRD patterns obtained fromsurfaces of sintered BZYNiO2 pellets before treatment in wet CO₂ at 700°C. for 100 h. The unit cells and lattice constants are summarized inTable 2.

FIG. 8b shows Rietveld refinement for XRD patterns obtained fromsurfaces of sintered BZYNiO2 pellets after treatment in wet CO₂ at 700°C. for 100 h. The unit cells and lattice constants are summarized inTable 2.

FIG. 9a shows surface SEM images of BZYNiO2 before treatment in wet CO₂at 700° C. for 100 h.

FIG. 9b shows surface SEM images of BZYNiO₂ after treatment in wet CO₂at 700° C. for 100 h.

FIG. 10 shows EDX spectra obtained from spots 1 (a), 2 (b), and 3 (c) inFIG. 9.

DEFINITIONS

Chemical elements are discussed in the present disclosure using theircommon chemical abbreviation, such as commonly found on a periodic tableof elements. For example, hydrogen is represented by its common chemicalabbreviation H; helium is represented by its common chemicalabbreviation He; and so forth.

As used herein, the prefix “nano” refers to the nanometer scale up toabout 100 nm. For example, particles having an average diameter on thenanometer scale (e.g., from about 0.1 nm to about 100 nm) are referredto as “nanoparticles.”

DETAILED DESCRIPTION

Reference now will be made to the embodiments of the invention, one ormore examples of which are set forth below. Each example is provided byway of an explanation of the invention, not as a limitation of theinvention. In fact, it will be apparent to those skilled in the art thatvarious modifications and variations can be made in the inventionwithout departing from the scope or spirit of the invention. Forinstance, features illustrated or described as one embodiment can beused on another embodiment to yield still a further embodiment. Thus, itis intended that the present invention cover such modifications andvariations as come within the scope of the appended claims and theirequivalents. It is to be understood by one of ordinary skill in the artthat the present discussion is a description of exemplary embodimentsonly, and is not intended as limiting the broader aspects of the presentinvention, which broader aspects are embodied exemplary constructions.

Composite metal-BZY-based membranes are expected to possess both highhydrogen permeation flux, mechanical strength, and chemical stability,which are the key factors for successful adoption of hydrogen permeationmembrane for practical applications. The metal here can be Nickel,Zirconium, Niobium, Tantalum, Yttrium, Palladium, Iron, Chromium,Cobalt, Vanadium, etc, or the binary alloy of these metals.

Metal-ceramic composite membranes are generally provided, along withtheir methods of preparation. In one embodiment, the metal-ceramiccomposite membranes includeM-BaZr_(1-x-y)Y_(x)T_(y))_(3-δ)where 0≦x≦0.5, 0≦y≦0.5; M is Ni, Zr, Nb, Ta, Y, Pd, Fe, Cr, Co, V, or acombinations thereof; and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu,Zn, Ga, In, Sn, or a combinations thereof. This structure is referred toherein as “M-BZYT”. In one embodiment, the volume ratio of BZYT isbetween about 40% and about 80% (e.g., about 40% to about 70% byvolume).

The M-BZYT membranes show excellent high hydrogen permeation flux andchemical stability in H₂O, CO₂, H₂S and other contaminants. Commercialmetal powder is used as source of metal phase. Sintering-active BZYpowders and metal powders are mixed, pressed, and sintered to obtaindense composite membranes. The membranes shows stable performance in thepresence of concentrated CO₂, H₂S.

The invention provides composite membranes based on metal and perovskiteoxide BZY for hydrogen permeation. Hydrogen can diffuse through themembrane in the form of atoms through metal phase or protons throughBZYT phase. The critical properties of the membranes include permeationflux, chemical stability in H₂O, CO₂, and H₂S-containing atmosphere.

The invented membranes are useful for extracting hydrogen from any feedstream containing hydrogen with a pressure between 1 and 1000 psi at atemperature between 600 and 1000° C. Theoretically, 100% pure hydrogenis obtained because the membranes are dense and allow no other gas topass through. The flux of the membrane can be affected by manyparameters, including phase composition of BZYT phase, volume ratio ofmetal and BZY, membrane thickness, temperature, and humidity content infeed gas.

The method of forming such membranes can include mixing a metal and aBZYT powder, pressing, and sintering at temperature between about 1100°C. and about 1700° C. The sintering atmosphere can be reducingatmosphere (e.g., 5% H₂/N₂). The atmosphere can also be first in inertgas (N₂, Ar, etc) and then in reducing atmosphere containing hydrogen(e.g., 5% H₂/N₂).

EXAMPLES

Hydrogen separation membranes based on high temperature protonconductors have been pursued for a long time because of its potential togreatly reduce the energy and capital cost of large-scale hydrogenproduction from steam methane reforming (SMR). A key to their successfulapplications is the development of a membrane with high performance,chemical and mechanical stability. Yttrium-doped barium cerate (BCY)possesses high proton conductivity but poor chemical stability in H₂Oand CO₂. Numerous efforts have been devoted to the improvement of itschemical stability, mainly through the partial replacement of Ce bycations such as In, Sn, Ti, Zr, Nb, Ta, etc. The performance ofNi—BaCe_(0.8)Y_(0.2)O_(3-δ) (Ni-BCY) andNi—BaZr_(0.1)Ce_(0.7)Y_(0.2)O_(3-δ) (Ni—BZCY) degraded ˜100% and 43%,respectively, in wet 40% H₂ and 30% CO₂ at 900° C.

Another strategy is to develop hydrogen separation membranes withchemically stable proton conductors such as Ln₆WO_(12-δ) (Ln refers tolanthanides), Ca-doped LaNbO₄, andNi—La_(0.4875)Ca_(0.0125)Ce_(0.5)O_(2-δ), but their performances arestill much inferior to that of Ni—BZCYYb, mostly due to their lowerproton and/or electronic conductivities. Y-doped BaZrO₃ (BZY) hasrecently been explored as a proton conductor for electrolyte of solidoxide fuel cells and hydrogen separation membranes because of itsexcellent bulk proton conductivity and chemical stability. SinceBaZr_(0.8)Y_(0.15)Mn_(0.05)O_(3-δ) (BZYM) shows very poor hydrogen fluxdue to the lack of electronic conductivity, dense composite Ni—BZYmembranes have been fabricated and demonstrated much higher hydrogenflux than that of BZYM. During the fabrication of BZY and Ni—BZYmembranes, the main obstacles are BZY's highly refractory nature, poorgrain boundary proton conductivity, and high number of grain boundariesdue to limited grain growth during sintering. One viable solution tothese problems is the adoption of sintering aids (e.g., NiO, ZnO, CuO,LiNO₃) which can significantly lower the sintering temperature of BZYand promote the grain growth. NiO has been reported as the mosteffective sintering aid in promoting the grain growth, which is crucialto reduce the large grain boundary resistance. Dense BZY ceramic withgrains as large as 5 μm can be achieved using BZY powders prepared bysolid state reactive sintering method with 1 wt. % NiO after sinteringat 1500° C. for 24 h, accompanied by the formation of a secondary phase,BaY₂NiO₅, which has a low melting point and promotes the sintering ofBZY. In our previous study, dense Ni—BZY membrane with large BZY grains(1-2 μm) was successfully fabricated using BZY powder prepared by solidstate reaction method with 2 wt. % NiO (denoted as BZYNiO₂) containingBaY₂NiO₅. In contrast, the BZY grains are very small (˜0.25 μm) in themembrane prepared using Ni—BZY powder obtained from the gel combustionmethod and subsequent reduction, which contains no BaY₂NiO₅. Apparently,BaY₂NiO₅ plays an important role in the fabrication of dense Ni—BZYmembrane with large BZY grains. These studies have mainly focused on thesintering behavior, microstructure, and electrical/permeationproperties. No work has been reported on the chemical stability of BZYand Ni—BZY in H₂, H₂O, and CO₂ after the introduction of the sinteringaids, which is crucial for their successful applications. Although theweight ratio of NiO sintering aid seems to be low, the weight ratio ofBaY₂NiO₅ is high due to the large difference in molecular weight betweenBaY₂NiO₅ (453.83 g/mol) and NiO (74.69 g/mol). If 2 wt. % NiO (based onthe total weight of BaCO₃, ZrO₂, and Y₂O₃) is completely converted toBaY₂NiO₅, there should be 13.8 wt. % BaY₂NiO₅ in the BZYNiO₂ ceramic.Unlike BZY, BaY₂NiO₅ may be unstable in H₂, H₂O, or CO₂-containingatmospheres at elevated temperatures, potentially leading to thechemical instability of BZYNiO₂ ceramic and Ni—BZY membrane, and thusinsulating phases will be formed on the surfaces and the performancewill degrade after exposure to H₂O and CO₂. Fortunately, this problemcan be mitigated by reducing the amount of BaY₂NiO₅ through tailoringthe BZY powders used in the fabrication process. In the Ni—BZY membraneprepared with BZYNiO₂ (denoted as Ni—BZY1), 2 wt. % NiO was directlymixed with BaCO₃, Y₂O₃, and ZrO₂ in the preparation of BZYNiO₂. A lot ofBaY₂NiO₅ is formed in the following calcination process. Ni—BZY2membrane is fabricated using BaZr_(0.8)Y_(0.2)O_(3-δ) prepared by solidstate reaction method without NiO (denoted as BZY20-SSR). However,BaY₂NiO₅ is still formed by the reaction among NiO (formed by partialoxidation of Ni during the sintering in N₂ containing a little oxygen),residual BaCO₃, and Y₂O₃ in BZY20-SSR. Because the amount of BaCO₃ andY₂O₃ is much less than that in uncalcined BZYNiO2, the amount ofBaY₂NiO₅ in Ni—BZY2 should be less than that of Ni—BZY1. In order tofurther reduce the amount of BaY₂NiO₅, we employee BZY20 powder preparedby combined EDTA-citric (CEC) method (BZY20-CEC). CEC is a wet-chemicalmethod and the distribution of particles is much more homogeneous thanthat of solid state reaction. Therefore, BZY20-CEC is free of residualBaCO₃ and Y₂O₃ after calcination, and will not contribute to theformation of BaY₂NiO₅, which allows us to adjust the amount of BaY₂NiO₅by partially replacing BZY20-SSR with BZY-CEC. Therefore, another twoNi—BZY membranes were prepared by further replacing 60% and 80%BZY20-SSR powder in Ni—BZY2 by BZY20-CEC (denoted as Ni—BZY3 andNi—BZY4, respectively). The amount of BaY₂NiO₅ is expected to followthis order: Ni—BZY1>Ni—BZY2>Ni—BZY3>Ni—BZY4.

In this study, the performance stability of these Ni—BZY membranes wasevaluated in wet H₂ with and without CO₂ at 900° C. The chemicalstability of BaY₂NiO₅, BZYNiO2, and Ni—BZY was investigated in H₂, H₂O,and CO₂-containing atmospheres. A stable Ni—BZY membrane was developed,demonstrating excellent chemical and performance stability in thepresence of H₂, H₂O, and CO₂.

Experimental

FIGS. 5a and 5b show the schematic of the material synthesis andchemical stability test processes employed in this work. All chemicalswere purchased from Alfa Aesar with purity >99.5%. BZY powders wereprepared through the solid state reaction method using 0 and 2 wt. % NiOas sintering aid (denoted as BZY20 and BZYNiO2, respectively). Forsimplicity, only BZYNiO2 is shown in FIGS. 5a and 5b . Stoichiometricamounts of BaCO₃, ZrO₂, and Y₂O₃ were ball-milled in ethanol with ZrO₂balls for 24 h. 0 and 2 wt. % NiO based on the total weight of BaCO₃,ZrO₂, and Y₂O₃ were added to the powder mixture prior to theball-milling to obtain BZY20 and BZYNiO2 powders, respectively. Theball-milled powders were dried and then pressed into pellets followed bycalcination at 1300° C. for 10 h. The calcined pellets were milled toobtain BZY20 and BZYNiO2 powders, respectively. To obtain dense BZYNiO2ceramic, calcined and milled BZYNiO2 powders were pressed into pelletsand then sintered at 1500° C. for 10 h in air. Some BZY20 powder wasalso prepared by the combined EDTA-citric acid (CEC) method and calcinedat 1100° C. for 10 h (denoted as BZY20-CEC).

TABLE 1 List of abbreviations for Ni—BZY (volume ratio 40:60) membranesprepared with different types and amounts of BZY powders. AbbreviationBZY powders Ni—BZY1 BZYNiO2 Ni—BZY2 BZY20-SSR Ni—BZY3 40% BZY20-SSR, 60%BZY20-CEC Ni—BZY4 20% BZY20-SSR, 80% BZY20-CEC

To study the effect of phase composition on the chemical stability ofNi—BZY membranes, different BZY powders with different weight contentswere used to fabricate 4 different Ni—BZY membranes (as listed in Table1). Calculated amounts of BZYNiO2, BZY20, and BZY20-CEC powders weremixed with Ni powders in volume ratio of 60:40 (ceramic vs Ni). Thesepowders were ball-milled, dried, milled, and pressed into pellets with a20-mm stainless steel die under the pressure of 100 MPa. These pelletswere sintered at 1440° C. for 20 h in N₂ and another 20 h in 5% H₂/N₂.During the sintering process in N₂ (contains ˜0.02 vol % O₂, measured bygas chromatography), partial Ni was oxidized to NiO which reacted withresidual BaCO₃ and Y₂O₃, forming BaY₂NiO₅ and promoting thedensification and grain growth of BZY phase. During the sinteringprocess in 5% H₂/N₂, residual NiO was reduced to Ni and BaY₂NiO₅decomposed forming Ni and a secondary phase. The reduction was confirmedby the increase of water content from ˜0.3% to ˜2.4% in the gas afterswitching N₂ to 5% H₂/N₂, monitored by a humidity sensor (VaisalaHMT338). The extended sintering time in 5% H₂/N₂ allowed the eliminationof pores generated by the decomposition of BaY₂NiO₅.

The sintered BZYNiO2, Ni—BZY pellets were polished on a Buehler polisherwith SiC sandpapers (320, 600, 1200 grits) and then diamond dispersionsolution (9, 3, 1 μm) to reveal the surface microstructure. PolishedBZYNiO2 pellet was annealed in wet CO₂ (3% H₂O) at 700° C. for 100 h tostudy its chemical stability in CO₂. A polished Ni—BZY1 sample wasthermally etched at 1300° C. for 30 min in 5% H₂/N₂ for surfacemicrostructure study. To test the chemical stability in water, thepolished Ni—BZY pellets (˜1 g in weight) were boiled in 30 mL deionizedwater for 20 h in Teflonlined stainless steel autoclaves. The polishedNi—BZY samples were also annealed in a gas mixture containing 3 vol %H₂O, 17 vol % H₂ and 80 vol % CO₂ at 900° C. for 50 h to test thechemical stability in wet CO₂.

BaY₂NiO₅ was synthesized by the solid state reaction (SSR) method.Stoichiometric amounts of BaCO₃, Y₂O₃, and NiO powders were ball-milledfor 24 h in ethanol with ZrO₂ balls for 24 h. The powders were dried,pressed into pellets, and calcined at 1300° C. for 10 h. The pelletswere milled into powders and then annealed in either dry/wet H₂ at 900°C. for 20 h, or wet CO₂ at 900° C. for 10 h. X-ray diffraction (XRD,Rigaku D/Max 2100, with Cu Ka radiation) analysis was used to identifythe phases present in the powders and pellets. Rietveld refinements werecarried out with GSAS package. Field emission scanning electronicmicroscopy (FESEM, Zeiss ultra plus) equipped with Energy-dispersiveX-ray spectroscopy (EDX, Oxford) was used to study the microstructureand composition of the BZY and Ni—BZY membranes.

Results and Discussion:

Performance stability in wet H₂

FIG. 2 shows the time dependence of hydrogen flux of various Ni—BZYmembranes at 900° C. in wet 20% H₂ (containing 3 vol % H₂O). The initialperformance of the membranes follows such an order:Ni—BZY1>Ni—BZY3>Ni—BZY4 (3.6, 2.8, and 2.0*108 mol/cm²s, respectively).In order to find the reason for the different initial flux, weinvestigated the microstructure of the membranes.

All membranes are composed of large Ni grains and small BZY grains. Thegrain sizes of BZY are estimated to be 1.44, 1.17, and 0.78 μm forNi—BZY1, Ni—BZY3, and Ni—BZY4, respectively. Similar trend is observedfor the permeation flux and grain size of BZY in Ni—BZY membranes. It iswell-known that BZY possesses high bulk proton conductivity but suffersfrom poor grain boundary proton conductivity. Therefore, BZY ceramicwith larger grain size and fewer grain boundaries also shows largertotal proton conductivity than that with small grain size. Since theNi—BZY membranes show the same behavior with BZY ceramics, the higherinitial flux of Ni—BZY membranes with larger BZY grains is attributed totheir fewer grain boundaries and higher total proton conductivities. Thedifference in grain sizes is due to the difference in the amount ofBaY₂NiO₅ formed during the sintering process in N₂, and BaY₂NiO₅promotes the grain growth of BZY phase.

The flux of Ni—BZY1 first degrades quickly and then slowly, with a totalflux loss of 21.5% in 180 h. The flux of Ni—BZY3 degrades 15.0% in 200h. However, the flux of Ni—BZY4 keeps stable during the whole testprocess (˜160 h). It seems that there is a trade-off between the initialflux and performance stability of these membranes. Since both Ni and BZYare thermodynamically stable in H₂ and H₂O, it's hard to explain thedegradation behavior. Therefore, the phase composition andmicrostructure was investigated of Ni—BZY1 membrane after the permeationtest. Unlike the fresh membrane which only consists of Ni and BZY, thetested feed and sweep side surfaces contain much less BZY. Both BaCO₃and YOOH are found on the feed and sweep side surfaces. The SEM imagesshowed that the feed side surface is completely covered by new phaseswith plate-like structure, while the sweep side surface is onlypartially covered. EDX results showed that the plate-like phases containBa, C, Y, and O, indicating that they are BaCO₃ and YOOH, as revealed bythe XRD results. Since the feed gas is wet H₂ without CO₂, BaCO₃ isformed by reaction between Ba(OH)₂ and CO₂ in air after the permeationtest. These insulating phases (Ba(OH)₂ and YOOH) can block the pathwaysfor hydrogen permeation, which explains the degradation behavior, butthe sources of these insulating phases are still unclear. To obtain moreinsight in the sources of Ba(OH)₂ and YOOH, we investigated the chemicalstability of Ni—BZY membranes by treating them in boiling water for 20 hor wet 17 vol % H₂ and 80 vol % CO₂ at 900° C. for 50 h.

Results and Discussion:

Chemical Stability in Boiling Water and Wet CO₂

The SEM images obtained from polished surface of fresh Ni—BZY1, 2, 3,and 4 membranes showed many small (˜3 μm) bumps were found on thesurface of Ni—BZY1. SEM-EDX analysis of polished Ni—BZY1 membrane showsthat these bumps contain Ba, C, and Y, but no Ni, which can be BaCO₃ andY₂O₃. EDX mapping results show that the porous clusters are rich in Ybut are depleted of Ba, indicating that these clusters are Y₂O₃. Thiscan be explained by the decomposition of BaCO₃ at 1300° C. formingvolatile BaO, which evaporates to the atmosphere and leaves Y₂O₃ behind.These results suggest that the secondary phases formed in thefabrication process are ready to react with H₂O/CO₂ in air even at roomtemperature, forming BaCO₃ and Y₂O₃, which grow out of the polishedsurface. Unlike the small bumps found in Ni—BZY1, a few large (˜20 μm)bumps with cracks were found on the surface of Ni—BZY2. There were muchfewer bumps on the surface of Ni—BZY3, and it's difficult to find thebumps on the surface of Ni—BZY4. Therefore, the number of bumps and theamount of secondary phases follow such an order:Ni—BZY1>Ni—BZY2>Ni—BZY3>Ni—BZY4.

FIG. 6 shows the XRD pattern obtained from surface of Ni—BZY1 (a) aftertreatment in boiling water for 20 h (Similar results are also obtainedfor Ni—BZY2, 3, and 4). Only peaks of Ni and BZY are present in bothpatterns, confirming that the Ni and BZY phases are stable in boilingwater. However, the pH value of the deionized water used in the boilingtest for Ni—BZY1 and Ni—BZY2 increased from 7 to 12. Precipitate wasobserved after H₂SO₄ was added to the water, indicating formation ofBaSO₄ (the sulphates of Ni, Y, Zr were all soluble in water). Theseresults suggested that Ba(OH)₂ was formed during the boiling of themembranes. Because Ba(OH)₂ was soluble in water and the polished surfacewas very smooth, its amount on the membrane surface was too low to bedetected by XRD. On the other hand, the pH value of water for boilingNi—BZY3 and Ni—BZY4 kept at ˜8, suggesting very small amount of Ba(OH)₂was formed during the boiling process. After boiling test, significantmicrostructure damage was observed on the surfaces of Ni—BZY1 andNi—BZY2 membranes. The characteristics of the surface microstructuredamage agree very well with the sizes and distribution of secondaryphases, such as small dotted bumps in boiled Ni—BZY1 and small dottedbumps in polished Ni—BZY1, large cracks in boiled Ni—BZY2 and largebumps in polished Ni—BZY2. A close look at the small bumps on boiledsurface of Ni—BZY1 showed that they consist of BZY grains in the bottomand Y₂O₃ on the top. In contrast, Ni—BZY3 and Ni—BZY4 showed no cracksor bumps. These results suggest the secondary phases in Ni—BZY1 reactedwith H₂O forming a lot of Ba(OH)₂ and Y₂O₃, which can explain theformation of insulating phases on the membrane surfaces and thus theperformance degradation in wet H₂.

XRD patterns in FIG. 6 show that a significant amount of BaCO₃ wasdetected on Ni—BZY1 and less was found on Ni—BZY2 after annealing in wet80% CO₂. Surprisingly, no BaCO₃ was found on Ni—BZY3 and Ni—BZY4. Thiswas further verified by SEM images. Most of the surfaces of Ni—BZY1 andNi—BZY2 membranes were covered by the new phases. EDX spectrum showedthat the new phases on Ni—BZY1 is composed of Ba, C, and O, which alsosuggests that the new phases is BaCO₃. However, there are only a littleBaCO₃ on Ni—BZY3, which is below the detection limit of XRD. ForNi—BZY4, no BaCO₃ is observed. The amount of BaCO₃ follows such order:Ni—BZY1>Ni—BZY2>Ni—BZY3>Ni—BZY4. It is noticeable that Ni—BZY4 showsexcellent chemical stability in both boiling water and wet CO₂.

Results and Discussion:

Performance Degradation and Chemical Instability

Results suggested that the performance degradation of Ni—BZY1 in wet H₂was caused by the blocking phases (Ba(OH)₂ and YOOH) formed on themembrane surfaces. The chemical stability study showed that Ba(OH)₂ andY₂O₃ was formed by the reaction between the secondary phases and water.Therefore, the flux degradation in wet H₂ was caused by Ba(OH)₂ and YOOHgenerated from the reaction between the secondary phase and H₂O. Themore secondary phases there are in Ni—BZY membranes, the moreBa(OH)₂+Y₂O₃ is formed when exposed to water, and the more theperformance degrades. The question is what the secondary phases are andwhere they come from. In the previous study, we observed BaY₂NiO₅ afterNi—BZY membranes were sintered in N₂ only. After the second sinteringprocess in 5% H₂/N₂, BaY₂NiO₅ disappeared but no new phase was found byXRD. It is difficult to identify the new phases directly because theyare mixed with large amount of Ni and BZY and are ready to react withH₂O/CO₂ in air. Therefore, we prepared BaY₂NiO₅ separately andinvestigated its chemical stability under various conditions.

FIG. 7 shows the XRD patterns of BaY₂NiO₅ before and after annealing indifferent atmospheres at 900° C. After calcination at 1300° C. for 10 h,Immm structured BaY₂NiO₅ with lattice parameters of a=3.757 Å, b=5.754Å, and c=11.315 Å is obtained. After annealing in CO₂ at 900° C. for 10h (FIG. 7, b), BaY₂NiO₅ powder decomposes into a mixture of BaCO₃, Y₂O₃,and NiO (BaY₂—NiO₅+CO₂=BaCO₃+Y₂O₃+NiO). After annealing in dry H₂ (FIG.7, c), BaY₂NiO₅ decomposes into BaY₂O₄ and Ni(BaY₂NiO₅+H₂=BaY₂O₄+Ni+H₂O). After annealing in wet H₂ (FIG. 7, d),aside from BaY₂O₄ and Ni, Y₂O₃ and BaCO₃ are found, suggesting thatBaY₂O₄ partially reacts with H₂O forming Y₂O₃ and Ba(OH)₂ which isconverted to BaCO₃ when exposed to air. These results indicate thatBaY₂NiO₅ is unstable in H₂, H₂O, and CO₂-containing atmospheres at 900°C., leading to the formation of insulating BaY₂O₄, Ba(OH)₂, and BaCO₃,respectively. Coors investigated reducedBaCe_(0.2)Zr_(0.6)Y_(0.2)O_(3-δ) (BCZY262, sintered with 1 wt. % NiO bysolid state reactive sintering method) by field emission SEM and highresolution transmission electron microscopy (HRTEM). Only Ni metallicnanoprecipitates and some amorphous grain boundaries were observed.Therefore, BaY₂NiO₅ was assumed to decompose into Ni, BaO, and Y₂O₃ inreducing atmosphere. Then BaO and Y₂O₃ were dissolved back to perovskitelattice. In that case, BZYNiO2 should be chemically stable, which cannotexplain the catastrophical failure of sintered BCZY262 ceramic duringcooling below 400° C. in wet H₂. Instead, the failure can be attributedto the stress originated from volume increase accompanied with thereaction between BaY₂O₄ and H₂O forming Ba(OH)₂ and Y₂O₃. BaY₂O₄ can beprepared by calcination of BaCO₃ and Y₂O₃ at 1000° C. for 10 h,suggesting that BaY₂O₄ is more stable than BaO (from the composition ofBaCO₃) and Y₂O₃ at elevated temperature in H₂O/CO₂-free condition.Therefore, after sintering in N₂ and then 5% H₂, BaY₂NiO₅ in Ni—BZYdecomposes into BaY₂O₄ and Ni, rather than BaO, Y₂O₃, and Ni.Unfortunately, both BaY₂O₄ and BaY₂NiO₅ easily react with H₂O and CO₂,forming insulating phases.

These results can provide a clear explanation on the performance andchemical instability found in Ni—BZY1, 2, and 3 membranes. In Ni—BZY1,BaY₂NiO₅ is formed during the fabrication of BZYNiO2 powder. In Ni—BZY2,3, and 4, residual BaCO₃ and Y₂O₃ in BZY20 prepared by the SSR methodreacts with NiO (from the oxidation of partial metal Ni in N₂ containing0.02% O₂) forming BaY₂NiO₅. BaY₂NiO₅ is reduced to BaY₂O₄ and Ni duringsintering in 5% H₂/N₂. BaY₂O₄ is distributed as isolated islands andreact with H₂O during permeation test in H₂, forming insulating bariumand yttrium hydroxides on the membrane surfaces and causing theperformance degradation. BaY₂O₄ reacts with H₂O and CO₂ formingBa(OH)₂+Y₂O₃ and BaCO₃+Y₂O₃ during the chemical stability test inboiling water and wet CO₂, respectively. Less BaY₂O₄ will lead to lessinsulating phases on the membrane surfaces and less performancedegradation when exposed to H₂O and CO₂, as observed in the performanceand chemical stability study. In Ni—BZY3 and Ni—BZY4, the BZY20-CECgrains also act as a covering layer for BaY₂O₄, and keeps BaY₂O₄ awayfrom attack by CO₂ and H₂O, leading to higher chemical stability.Similar strategy has been employed in aBaCe_(0.8)Sm_(0.2)O_(3-δ)—Ce_(0.8)Sm_(0.2)O_(2-δ) composite electrolyteand successfully avoided the chemical instability issue of BaCeO_(3-δ).Apparently, the amount of BaY₂O₄ is too large to be fully covered byBZY20-CEC in Ni—BZY3, but is small enough to be fully covered byBZY20-CEC in Ni—BZY4. We also tried to prepare Ni—BZY membrane only withBZY20-CEC powder, however, the obtained membrane possessed significantporosity due to lack of BaY₂NiO₅ as sintering aid. The Ni—BZY4 membranedemonstrated both excellent chemical stability and sinteractivity, andits performance stability was further tested in wet CO₂.

Results and Discussion:

Performance and Microstructural Stability of Ni—BZY4 Membrane in Wet CO₂

Hydrogen separation membranes are expected to be applied in wet H₂ withconsiderable amount of CO₂. Therefore, its performance stability in CO₂is critical to its application. FIG. 3 shows that the flux of Ni—BZY4membrane in 40% H₂ increases from 2.5*10⁸ to 2.8*10⁸ and 2.9*10⁸mol/cm²s after introduction of 30% and 50% CO₂, respectively. Except forthe initial flux increase, the flux keeps stable during the test in wetCO₂ for 225 h. The flux increase is ascribed to the reverse water gasshift (RWGS, H₂+CO₂→H₂O+CO) reaction which leads to the increase ofmoisture content in feed gas and thus proton conductivity in BZY phase,which is previously observed in Ni—BZCYYb membrane. The RWGS reactionconsumes equal amount of H₂ and CO₂, generating same amount of H₂O andCO. The measured CO content is 1.9% after the introduction of 30% CO₂,indicating that the moisture content increases from 3% (from the waterbubbler) to 4.9%, and the hydrogen content decreases from 40% to 38.1%.The former is beneficial for the increase of the proton conductivity ofBZY and hydrogen flux, while the latter is deleterious to hydrogen fluxby reducing hydrogen partial pressure gradient across the membrane.Nevertheless, the flux increases, suggesting the former is dominant inthe case of Ni—BZY4 membrane. In a very recent report, Zhu et al.developed a dense Ni—BaZr_(0.7)Pr_(0.1)Y_(0.2)O_(3-δ) (Ni—BZPY) membraneutilizing the benefit of Pr-doping on the sinter-activity of BZY.Because Pr⁴⁺ can easily be reduced to Pr³⁺ and even Pr²⁺, the doping ofPr in BZY introduces additional oxygen vacancies, which can promote theRWGS reaction, as observed in Ce-doped BZY. The hydrogen content in feedgas decreased dramatically from 40% to 28% after introduction of 30% CO₂at 850° C. Therefore, the flux decreased from 7.3*10⁻⁹ to 6.1*10⁻⁹mol/cm²s. Besides, the flux of a 0.40-mm-thick Ni—BZPY membrane in wet40% H₂ at 900° C. was only 9.2*10⁻⁹ mol/cm²s, much lower than that ofNi—BZY4 membrane (2.5*10⁻⁸ mol/cm²s in the same condition). Therefore,Ni—BZY4 is superior to Ni—BZPY membrane in both performance andperformance stability.

After permeation test in wet CO₂, the microstructure of Ni—BZY4 membranewas investigated by SEM, which showed that the whole membrane is stillcompact and no obvious porosity is observed. There is no coarsening ofNi particles close to the feed side surface. Only peaks of Ni and BZYcan be found in the XRD pattern obtained from the feed side surface. Thefeed side surface consists of large Ni particles and small BZY grains.In comparison, the feed side surface of Ni—BZY1 membrane are completelycovered by plate-like phases including BaCO₃ and YOOH after test in wetH₂, which is much milder than wet 50% CO₂. Although the surface looksporous, the cross-sectional view shows the porous layer only reaches adepth of several microns. Similar microstructure is observed on thesweep side of the membrane.

After permeation test in wet CO₂, the microstructure of Ni—BZY4 membranewas investigated by SEM, which shows that the whole membrane is stillcompact and no obvious porosity is observed. There is no coarsening ofNi particles close to the feed side surface. Only peaks of Ni and BZYcan be found in the XRD pattern obtained from the feed side surface(FIG. 4). The feed side surface consists of large Ni particles and smallBZY grains. In comparison, the feed side surface of Ni—BZY1 membrane arecompletely covered by plate-like phases including BaCO₃ and YOOH aftertest in wet H₂, which is much milder than wet 50% CO₂. Although thesurface looks porous, the cross-sectional view shows the porous layeronly reaches a depth of several microns. Similar microstructure isobserved on the sweep side of the membrane.

Results and Discussion:

Implication on the Feasibility of Using BZYNiO2 as Electrolyte for SOFCs

An important implication of this study is that BaY₂NiO₅ can react withCO₂ forming BaCO₃ and Y₂O₃, this may be a serious problem for BZYNiO2,which is proposed as a promising electrolyte material with greatsinter-activity and high electrical conductivity. Until now, no studyhas been reported on its chemical stability, which is crucial for itssuccessful application. Rietveld refinements of the XRD profiles in FIG.8a show that fresh BZYNiO2 consists of BZY and BaY₂NiO₅. After annealingin wet CO₂ at 700° C. for 100 h, BaY₂NiO₅ disappears but BaCO₃ and Y₂O₃are found (FIG. 8b ). SEM image in FIG. 9 showed that the polishedsurface of BZYNiO2 before exposure to CO₂ is very dense. It isnoticeable that some dark spots are randomly distributed in the ceramicmatrix. EDX spectra in FIGS. 10a and b , show that the dark phaseconsists of Ba, Y, Ni, and O, while the light phase consists of Ba, Zr,Y, and O. Considering the XRD results, the dark and light phases areBaY₂NiO₅ and BZY, respectively. After annealing in wet CO₂, the surfaceof BZYNiO2 is covered by many crystal-like particles with a size rangingfrom hundreds of nanometers to a few microns. The EDX spectrum in FIG.10c shows that the particles mainly contain Ba, C, Y, and O, suggestingthat they are BaCO₃ and Y₂O₃. It can be seen from the coverage that theamount of BaCO₃ and Y₂O₃ is much more than that of BaY₂NiO₅ on the freshmembrane surface, probably due to diffusion of Ba²⁺ from BaY₂NiO₅ insidethe BZYNiO2 ceramic. One may ask whether Ba-excessive BZY contribute tothe formation of BaCO₃. This is unlikely because there should be asignificant change in the lattice parameter if Ba-excessive BZY reactswith CO₂, however, there is almost no change in the lattice parameter ofBZY phase (obtained from Rietveld refinement of XRD profiles of BZYNiO2before and after the annealing in wet CO₂, 4.208 and 4.206 Å,respectively, FIGS. 8a and b ). These results clearly suggest thatBaY₂NiO₅ in BZYNiO2 makes it chemically instable in H₂O/CO₂, which needsto be resolved before it is used as electrolyte for solid oxide fuelcells. This problem may be solved by a similar strategy as that inNi—BZY4. BZYNiO2 prepared by solid state reaction method can cause theformation of BaY₂NiO₅ which is an efficient sintering aid but also causechemical instability, and BZY prepared by CEC method is chemicallystable but not sinter-active. The combination of these powders can leadto a chemically stable yet still sinter-active proton conductor.

TABLE 2 Lattice constants of phases in fresh and annealed BZYNiO2determined by Rietveld refinement of XRD patterns in FIG. 8. SamplePhase Unit cells Lattice constants (Å) Fresh BZYNiO2 BZY Cubic (Pm3m)4.208 BaY₂NiO₅ Orthorhombic a = 3.757, b = 5.755, (lmmm) c = 11.320Annealed BZY Cubic (Pm3m) 4.206 BZYNiO2 BaCO₃ Orthorhombic a = 5.306, b= 8.891, (Pmcn) c = 6.471 Y₂O₃ Cubic (la3) 10.595 

CONCLUSIONS

Although BZY possesses excellent chemical stability in H₂O and CO₂, BZYceramic and Ni—BZY membranes sintered using NiO sintering aid arechemically instable because of the formation of BaY₂NiO₅. BaY₂NiO₅reacts with H₂, H₂O, and CO₂, forming insulating BaY₂O₄, Ba(OH)₂, andBaCO₃ phases, respectively. Previous report suggested that BaY₂NiO₅ wasreduced to BaO and Y₂O₃, which were dissolved back to BZY lattice.However, we find that Ni—BZY membranes contain BaY₂O₄ islands afterreduction. Both BaY₂NiO₅ and BaY₂O₄ easily react with H₂O and CO₂forming Ba(OH)₂ and BaCO₃, respectively. Therefore, both BZYNiO2 andNi—BZY are chemically instable in wet CO₂, and the hydrogen flux ofNi—BZY membranes degraded significantly in wet H₂ at 900° C. Acomparative study shows that the more BaY₂O₄ there is in Ni—BZYmembranes, the less stable they are. The chemical instability greatlyrestricts the applications of BZYNiO2 and Ni—BZYNiO2 as electrolytes forsolid oxide fuel cells and hydrogen separation membranes, respectively.Fortunately, the chemical stability of Ni—BZY membranes can be improvedby reducing the amount of BaY₂O₄ formed in the fabrication process. Thisis achieved by replacing a portion of BZY20 powder in the startingmaterial with BZY20-CEC powder. The BZY20-CEC grains also act as acovering layer for BaY₂O₄ and helps avoid the reaction between BaY₂O₄and H₂O/CO₂. The new Ni—BZY4 membrane fabricated with 20% BZY20-SSR and80% BZY20-CEC powders demonstrated very stable and improved permeationflux in wet 50% CO₂ at 900° C. The phase composition and membranemicrostructure were also intact after the test, indicating its excellentchemical stability, surpassing previous Ni—BZCYYb membrane. It alsopossesses much higher hydrogen flux than Ni—BZPY. These factsdemonstrate that Ni—BZY4 is very promising for hydrogen permeationapplications.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood the aspects of the various embodiments may beinterchanged both in whole or in part. Furthermore, those of ordinaryskill in the art will appreciate that the foregoing description is byway of example only, and is not intended to limit the invention sofurther described in the appended claims.

What is claimed:
 1. A hydrogen permeation membrane, comprising: a metaland a ceramic material mixed together, wherein the metal comprises Ni,and wherein the ceramic material has the formula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ) where 0<x≦0.5, 0≦y≦0.5, 0<(x+y)<1;0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu, Zn, Ga, In,Sn, or combinations thereof, wherein at least a portion of the ceramicmaterial is prepared with EDTA, citric acid, or a combination thereofprior to mixing with the metal.
 2. The hydrogen permeation membrane ofclaim 1, comprising the ceramic material in about 40% to about 80% byvolume.
 3. The hydrogen permeation membrane of claim 1, wherein thehydrogen permeation membrane has a thickness of about 0.01 mm to about10 mm.
 4. The hydrogen permeation membrane of claim 1, where 0<y≦0.5. 5.The hydrogen permeation membrane of claim 4, where 0<δ≦0.5.
 6. A methodof forming a membrane, comprising: mixing a metal and a ceramic powderto form a metal-ceramic mixture, wherein the metal comprises Ni;pressing the metal-ceramic mixture to form a composite membrane; andsintering the metal-ceramic mixture at a temperature of about 1100° C.to about 1700° C., wherein the ceramic powder comprises a ceramicmaterial having the formula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ) where 0<x≦0.5, 0≦y≦0.5, 0<(x+y)<1;0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu, Zn, Ga, In,Sn, or combinations thereof, wherein at least a portion of the ceramicpowder is prepared with EDTA, citric acid, or a combination thereof. 7.The method of claim 6, wherein the metal-ceramic mixture is sintered ina reducing atmosphere.
 8. The method of claim 7, wherein the reducingatmosphere comprises H₂.
 9. The method of claim 6, further comprising:heating the metal-ceramic mixture is in an inert atmosphere prior tosintering in the reducing atmosphere.
 10. The method of claim 9, whereinthe inert atmosphere comprises N₂.
 11. The method of claim 9, whereinthe inert atmosphere comprises Ar.
 12. The method of claim 6, where0<y≦0.5.
 13. The method of claim 12, where 0<δ≦0.5.
 14. The method ofclaim 6, wherein the metal and the ceramic powder are mixed such thatthe metal-ceramic mixture comprises the ceramic material in about 40% toabout 80% by volume.
 15. A method of extracting hydrogen from a feedstream, comprising: exposing the feed stream to a first side of amembrane at a temperature of about 600° C. to about 1000° C., whereinthe feed stream comprises hydrogen; and collecting pure hydrogen gasfrom a second side of the membrane opposite of the first side, whereinthe membrane comprises a metal and a ceramic material, wherein the metalcomprises Ni, and wherein the ceramic material has the formula:BaZr_(1-x-y)Y_(x)T_(y)O_(3-δ) where 0<x≦0.5, 0≦y≦0.5, 0<(x+y)<1;0≦δ≦0.5, and T is Sc, Ti, Nb, Ta, Mo, Mn, Fe, Co, Ni, Cu, Zn, Ga, In,Sn, or combinations thereof, wherein at least a portion of the ceramicmaterial is prepared with EDTA, citric acid, or a combination thereofprior to mixing with the metal.
 16. The hydrogen permeation membrane ofclaim 1, wherein the grain size of the ceramic material is less than orequal to 1.17 μm.
 17. The hydrogen permeation membrane of claim 1,wherein a portion of the ceramic material is not sinter-active.
 18. Thehydrogen permeation membrane of claim 1, wherein the ceramic materialcomprises BaZr_(0.8)Y_(0.2)O_(3-δ).